Since you are so far into it, how about torching the rod the slide hammer is connected to off of the tube and welding on a 1/2-20 nut. Screw a bolt into the nut and against the end of the shaft.

Like Freiburger says, fix it with fire.

Those keys are fairly soft aren't they? Couldn't you grind it flush, drill it, take a small chisel and release it from the sprocket, pull the sprocket off, and then put a new key in?

Or make a puller by taking a piece of plate steel, drill a hole in it, grind a flat spot to grab the head of the key, drill and tap three holes, insert bolts long enough to contact the sprocket plus some threads and tighten each bolt until the key pulls out.

Turn the gib key into a bolt on the bottom of a motorcyle. It will fall right out.
:)

Connect your stick welder directly to the key, ground on the chain drive. Pulse the machine on/off until the key is cherry red. Spray it with penetrating oil while it's hot.

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Still no love from this piece of 5hit. Heat is next.

I have one of those big pry bars - they are about 6' long and weigh a lot. Somehow if you could get one of those in there along with heat to the sprocket and ice on the key.......

^^^ I started with the pry bar. If I don’t get it, I’m cutting the sprocket to remove it.

The time invested already exceeds the value of the sprocket.

I still think a drill and chisel would get it. Maybe some heat on the head of the pin and let it transfer through the pin. Surprised the two bolts applying pressure and the puller didn't work.

I love/hate challenges like this. I know that feeling of frustration well. Being WAY, WAY beyond any reasonable effort to resolve what should be a simple task. The good news is that is feels THAT much better when you do claim victory!!!

If that sprocket is readily available, I'm in heat first, cut second camp.

Good luck. Keep us posted!

JA

Have you trying changing up the order of the curse words you're using? Or maybe throwing something at it in disgust? :D

You probably have, but have you sourced a replacement gear yet? Seems like 1/2 the time I can find a direct replacement, and the other 1/2 I have to fabricate something.

If you aren't having luck, try talking like this guy when you're working on it. Pure frontier jibberish. He's a trip! :D

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You need to go buy a new sprocket and key. Then give the old key one last gentle pull....it'll probably jump out :D

If you have a tractor supply near you they usually have a pretty good selection of sprockets and such for farm implements.
Good luck
Tony

Sounds just like the agricultural engineers around here!

Sometimes you have to get western...

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http://forums.pelicanparts.com/uploa...1596419721.jpg

Atta boy, Scott...

Did you do the right one?

The upper one looks like it needs replacing first. 😂

http://forums.pelicanparts.com/uploa...1596421416.jpg